Exhaust baffle component for an air turbine assembly

ABSTRACT

A baffle component for a turbine starter includes a first baffle level and a second baffle level stacked with the first baffle level. The first baffle level and the second baffle level may be arranged with a starter assembly such that airflow entering the baffle levels is directed by the first baffle level and the second baffle level to exit the starter assembly.

CROSS-RELATED TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.63/000,107 filed Mar. 26, 2020, the contents of which are incorporatedherein by reference in its entirety.

BACKGROUND

Exemplary embodiments pertain to the art of starter assemblies forengines, such as gas turbine engines and, more particularly, to exhaustbaffle components to assist in directing airflow within a starterassembly of the engine.

Many relatively large gas turbine engines, including turbofan engines,may use an air turbine starter (ATS) to initiate gas turbine enginerotation. The ATS is typically mounted on an accessory gearbox which, inturn, is mounted on the engine or airframe. Consequently, the ATS isinstalled in the aircraft at all times even though active operation mayoccur only for a minute or so at the beginning of each flight cycle,along with occasional operation during engine maintenance activities.

The ATS generally includes a turbine section coupled to an outputsection within a housing. The turbine section is coupled to a highpressure fluid source, such as compressed air, to drive the outputsection through a gear system. Thus, when the high pressure fluid sourceimpinges upon the turbine section, the output section powers the gasturbine engine. The ATS generally includes an exhaust baffle downstreamof the turbine section.

Current exhaust baffle assemblies for engine starters mount each ofseveral individual baffles in parallel with a mounting face of anengine. Such assemblies include many components such as spacers betweenthe individual baffles and are labor intensive to assemble. Further, dueto the many components and assembly challenges, the baffle component ofthe starter assembly may experience cracking during use.

BRIEF DESCRIPTION

According to some embodiments, exhaust baffles assemblies for a turbinestarter are provided. The baffles are configured to assist in directingairflow within a starter assembly of an engine. The baffle includes afirst baffle level and a second baffle level stacked with the firstbaffle level. The baffle levels are arranged with a starter assemblysuch that airflow entering the baffle levels is directed by the firstbaffle level and the second baffle level to exit the starter assembly.

In addition to one or more of the features described above, or as analternative, in further embodiments of the baffle, the first bafflelevel may include a plurality of first airflow channels and the secondbaffle level may include a plurality of second airflow channels. Inaddition, each of the plurality of first airflow channels share a wallwith one of the plurality of second airflow channels.

In addition to one or more of the features described above, or as analternative, in further embodiments of the baffle, the first airflowchannel of the plurality of first airflow channels is defined by a pairof fins spaced from one another and extending between the shared walland a lower wall.

In addition to one or more of the features described above, or as analternative, in further embodiments of the baffle, the first bafflelevel may include an upper outer edge and the shared wall extends fromthe upper outer edge.

In addition to one or more of the features described above, or as analternative, in further embodiments of the baffle, the first bafflelevel and the second baffle level may define a first attachment featureat a first end and a second attachment feature at a second end. Theattachment features are configured to facilitate a connection betweenadjacent baffle sections. The connected adjacent baffle sections definea substantially circular shape defining a first central axis.

In addition to one or more of the features described above, or as analternative, in further embodiments of the baffle, the baffle levels maybe arranged with one another such that a first airflow traveling throughthe first baffle level is in a direction substantially parallel with asecond airflow traveling through the second baffle level.

In addition to one or more of the features described above, or as analternative, in further embodiments of the baffle, the shared wall maybe oriented at an angle substantially between zero and ninety degreesrelative to the first central axis defined by the substantially circularshape.

In addition to one or more of the features described above, or as analternative, in further embodiments of the baffle, the baffle levels maybe arranged with one another such that airflow from the starter assemblyis exhausted via two airflow channels.

In addition to one or more of the features described above, or as analternative, in further embodiments of the baffle, the first bafflelevel and the second baffle level may be formed via additivemanufacturing.

In addition to one or more of the features described above, or as analternative, in further embodiments of the baffle, the first bafflelevel may include a plurality of first airflow channels and the secondbaffle level may include a plurality of second airflow channels. Inaddition, each first airflow channel of the plurality of first airflowchannels defines an airflow central plane and each second airflowchannel of the plurality of second airflow channels is orientedsubstantially parallel to the airflow central plane.

According to some embodiments, starter assemblies for turbines areprovided. The starter assembly includes a baffle component. The bafflecomponent includes a plurality of first airflow channels. The firstairflow channels are defined by a pair of fins spaced from one another,a lower wall, and a shared wall. In addition, the baffle componentincludes a plurality of second airflow channels. The second airflowchannels are defined by one of the pairs of fins and the shared wall.Further, each of the pairs of fins extend through the shared wall suchthat each of the pairs of fins partially define one of the plurality offirst airflow channels and one of the plurality of second airflowchannels.

In addition to one or more of the features described above, or as analternative, in further embodiments of the starter assembly, theplurality of second airflow channels may be arranged in a stack with theplurality of first airflow channels such that the shared wall partiallydefines each airflow channel of the plurality of first airflow channelsand partially defines each airflow channel of the plurality of secondairflow channels.

In addition to one or more of the features described above, or as analternative, in further embodiments of the starter assembly, the bafflecomponent may be arranged to define a central axis and the bafflecomponent further has one or more posts, each post of the one or moreposts extending through the baffle levels and being disposed equidistantfrom the central axis.

In addition to one or more of the features described above, or as analternative, in further embodiments of the starter assembly, the bafflecomponent may include a plurality of components. Each of the pluralityof components includes a first end for securing to a first adjacentcomponent and a second end for securing to a second adjacent component.

In addition to one or more of the features described above, or as analternative, in further embodiments of the starter assembly, theplurality of components may be arranged with one another to define asubstantially circular shape about a baffle central axis.

In addition to one or more of the features described above, or as analternative, in further embodiments of the starter assembly, theplurality of components may be arranged such that the baffle centralaxis is oriented substantially perpendicular to an axis of an adjacentengine.

In addition to one or more of the features described above, or as analternative, in further embodiments of the starter assembly, the bafflecomponent may include more than one baffle section. Each of the morethan one baffle sections are arranged with one another to define acentral axis and the shared wall is oriented at an angle substantiallybetween zero and ninety degrees relative to the central axis.

In addition to one or more of the features described above, or as analternative, in further embodiments of the starter assembly, eachairflow channel of the plurality of first airflow channels may influencea first airflow therethrough in a direction substantially parallel to anairflow direction of a second airflow traveling through each airflowchannel of the plurality of second airflow channels.

In addition to one or more of the features described above, or as analternative, in further embodiments of the starter assembly, the bafflecomponent may be formed via additive manufacturing.

In addition to one or more of the features described above, or as analternative, in further embodiments of the starter assembly, each firstairflow channel of the plurality of first airflow channels may define anairflow central plane and each second airflow channel of the pluralityof second airflow channels is oriented substantially parallel to theairflow central plane.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way.With reference to the accompanying drawings, like elements are numberedalike:

FIG. 1A is a side view, in partial cross-section, of an example of a gasturbine engine including a gear box and a starter assembly;

FIG. 1B is a perspective view of a starter assembly connected to a gearbox;

FIG. 2A is a perspective, partially exploded view of an example of aportion of a starter assembly of an engine;

FIG. 2B is a side view, in cross-section, of a portion of the starterassembly of FIG. 2A;

FIG. 3A is a perspective view of an example of a portion of a starterassembly of an engine;

FIG. 3B is a side view, in cross-section, of a portion of the starterassembly of FIG. 3A;

FIG. 4A is a perspective view of an exhaust baffle component of thestarter assembly of FIG. 3A;

FIG. 4B is a perspective view of a portion of the exhaust bafflecomponent of FIG. 4A; and

FIG. 4C is a side view, in cross-section, of a portion of the starterassembly of FIG. 3A illustrating an example of airflow influenced by theexhaust baffle component of FIG. 4A.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosedapparatus and method are presented herein by way of exemplification andnot limitation with reference to the Figures.

FIG. 1A schematically illustrates an example of a gas turbine engine 20.The gas turbine engine 20 includes a fan section 22, a compressorsection 24, a combustor section 26, and a turbine section 28. Each ofthe fan section 22, the compressor section 24, the combustor section 26,and the turbine section 28 is arranged with one another to define anengine central longitudinal axis A

In some cases, a gear box 100 may be mounted to a housing of the gasturbine engine 20 at a location adjacent one of the compressor section24, the combustor section 26, or the turbine section 28 to facilitatemechanical communication between the engine and the gearbox.

FIG. 1B is a perspective view showing the gear box 100 connected to astarter assembly 102 of FIG. 1A. In one example, the starter assembly102 may be an air turbine starter. Components of the gear box 100 may bearranged with components of the gas turbine engine 20 to transfermechanical energy between the gas turbine engine 20 and the starterassembly 102 in either direction. While the starter assembly 102 isshown in communication with the gas turbine engine 20 in FIG. 1A, thosein the art will appreciate that the starter assembly 102 may operatewith other types of engines without departing from a scope of thepresent disclosure.

FIGS. 2A and 2B show an example of a starter assembly of a gas turbineengine, referred to generally as a starter assembly 200 herein. In oneexample, the starter assembly 200 may be an air turbine starter. Ahousing 202 defines an opening 204. The opening 204 defines a centralaxis 206. Air enters the housing 202 via the opening 204 in a directionsubstantially parallel to the central axis 206 as represented by arrow207 in FIG. 2A. Air exiting the housing 202 is represented by arrows 209in FIG. 2B and exits through spacing between baffle louvers describedbelow. Arrows 209 are also generally shown in FIG. 2a for context. Thestarter assembly 200 includes multiple additional components. Forexample, the starter assembly can include an exhaust baffle assembly208. The exhaust baffle assembly 208 includes separately formedcomponents such as a first baffle louver 210, a second baffle louver212, a third baffle louver 214, and a plurality of spacers 218. Each ofthese separately formed components must then be assembled with oneanother, a burdensome task. While the exhaust baffle assembly 208 isshown with three baffle louvers in FIGS. 2A and 2B, those skilled in theart will appreciate that the exhaust baffle assembly 208 may includemore than three baffle louvers.

FIG. 2B shows further detail related to an assembled version of theseparately formed components discussed above. The assembly processalternately stacks the baffle louvers and the spacers 218. Whenassembled, the baffle louvers are oriented with one another in anoverlap-fashion relative to airflow originating near the central axis206 and traveling toward the baffle assembly 208 as represented byarrows 222 in FIG. 2B. For example, air may travel from the opening 204to the baffle assembly 208 via a channel 223. When the air reaches thebaffle assembly 208, the overlap-fashion of the baffle louversinterferes with continuous exhaust airflow through the baffle assembly208 as all or most of the exhaust airflow contacts one of the firstbaffle louver 210, the second baffle louver 212, or the third bafflelouver 214.

FIGS. 3A and 3B illustrate an example of an engine starter assemblyaccording to the present disclosure, referred to generally as an enginestarter assembly 300 herein, and a portion of a baffle component for theengine starter assembly 300, referred to generally as a baffle component302 herein. The engine starter assembly 300 and the baffle component 302may be utilized in aircraft starters or other similar starters. Forexample, the starter assembly 300 may be coupled to a gear box inmechanical communication with an engine. The engine starter assembly 300may be mounted adjacent to a portion of the engine, such as the gear box100 described above in relation to the gas turbine engine 20.

The baffle component 302 may include a plurality of sections 404connected to one another or formed as a single component. Each section404 of the plurality of sections 404 may be spaced equidistant from astarter assembly central axis 310. In one example, each section 404 ofthe plurality of sections 404 may be arranged with one another to definea substantially circular shape about the starter assembly central axis310. In another example, the starter assembly central axis 310 may bedefined by an opening 311.

The baffle component 302 may be arranged with components of the enginestarter assembly 300 to assist in managing airflow direction therein.Air may travel from the opening 311 to the baffle component 302 via anair channel 312 as represented with arrows 313 in FIG. 3B. Air may enterthe starter assembly 300 at a location adjacent the starter assemblycentral axis 310 and travel in a direction parallel therewith asrepresented by arrow 314. Air may exit the starter assembly 300 via thebaffle component 302 as represented by arrow 315 of FIG. 3B.

Now additionally referring to FIGS. 4A and 4B, the baffle component 302may include a plurality of baffle sections 404 secured to one another orformed as a single unit. Each of the baffle sections 404 may be arrangedwith one another to define a substantially circular shape about thecentral axis 310. While FIG. 4A shows a plurality of baffle sections404, those skilled in the art will appreciate that there may be more orfewer baffle sections 404 of varying shapes based on available packagingspace and desired performance metrics without departing from a scope ofthe present disclosure.

The baffle component 302 may include one or more posts 406 to secure thebaffle component 302 to a supporting structure, such as a starterassembly. While shown as having a cylindrical shape in FIGS. 4A and 4B,those skilled in the art will appreciate that each of the one or moreposts 406 may have a different shape without departing from a scope ofthe present disclosure. The baffle component 302 may define one or morepost openings 407 to receive one of the one or more posts 406 or the oneor more posts 406 may be formed with the rest of the baffle component302 as a single unit. In one example, the baffle component 302 may beformed via additive manufacturing, for example layer-by-layer additivemanufacturing. Layer-by-layer additive manufacturing involves formingsuccessive layers on top of one another to form an object. In anotherexample, the baffle component 302 may be formed via a stamping process.

FIG. 4B is a perspective view of one of the baffle sections 404illustrating additional detail. Each of the baffle sections 404 may havemultiple baffle levels including a first baffle level 408 stacked with asecond baffle level 410. The first baffle level 408 may include aplurality of first airflow channels 414 and the second baffle level 410may include a plurality of second airflow channels 416.

Each airflow channel of the plurality of first airflow channels 414 andthe plurality of second airflow channels 416 may be defined by walls. Inone example, each airflow channel of the plurality of first airflowchannels 414 is partially defined by a shared wall 420. The shared wall420 may define a portion of each of the plurality of first airflowchannels 414 and each of the plurality of second airflow channels 416.The shared wall 420 may extend from an upper outer edge 424 of thebaffle component 302.

Fins 428 may be spaced from one another along the baffle component 302to further define the airflow channels. A lower wall 430 may extendabout the central axis 310 and further define each airflow channel 414of the plurality of first airflow channels 414. For example, a portionof the shared wall 420, a portion of the lower wall 430, and respectiveadjacent fins 428 may be arranged with one another to define one of theplurality of first airflow channels 414. In one example, each of thefins 428 may extend from the lower wall 430 to the shared wall 420. Eachof the fins 428 may define a portion of both of one of the plurality offirst airflow channels 414 and one of the plurality of second airflowchannels 416. In another example, fins 428 may be curved in thedirection of continuous exhaust airflow through baffle assembly 208 toavoid a sharp airflow turn.

The first baffle level 408 and the second baffle level 410 mayseparately or together define a first attachment feature at a first end460 and a second attachment feature at a second end 462. Each of theattachment features may be configured to facilitate connection betweenadjacent baffle levels and adjacent baffle sections 404 as shown in FIG.4A.

FIG. 4C illustrates a side view, in cross-section, of a portion of theengine starter assembly 300 including the baffle component 302 of FIG.4A, showing an example of fluid flow within the engine starter assembly300. Airflow traveling from the opening 311 to the baffle component 302via the air channel 312 is represented by arrow 313. Air exiting theengine starter assembly 300 via one of the plurality of first airflowchannels 414 and/or one of the plurality of second airflow channels 416is represented by arrows 350. In one example, the airflow represented byeach arrow 350 of arrows 350 may travel in a direction substantiallyparallel to one another along a first channel axis 352 and a secondchannel axis 354, respectively. In this example, a shared wall 320 maybe oriented at an angle 358 having a value substantially between zeroand ninety degrees. The angle 358 may be further defined by the firstchannel axis 352 and a face axis 361 defined by a face 363.

The term “about” is intended to include the degree of error associatedwith measurement of the particular quantity based upon the equipmentavailable at the time of filing the application.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the presentdisclosure. As used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,element components, and/or groups thereof.

While the present disclosure has been described with reference to anexemplary embodiment or embodiments, it will be understood by thoseskilled in the art that various changes may be made and equivalents maybe substituted for elements thereof without departing from the scope ofthe present disclosure. In addition, many modifications may be made toadapt a particular situation or material to the teachings of the presentdisclosure without departing from the essential scope thereof.Therefore, it is intended that the present disclosure not be limited tothe particular embodiment disclosed as the best mode contemplated forcarrying out this present disclosure, but that the present disclosurewill include all embodiments falling within the scope of the claims.

What is claimed is:
 1. A baffle component for a turbine startercomprising: a first baffle level; and a second baffle level stacked withthe first baffle level, wherein the levels are arranged with a starterassembly such that airflow entering the baffle levels is directed by thefirst baffle level and the second baffle level to exit the starterassembly.
 2. The baffle component of claim 1, wherein the first bafflelevel includes a plurality of first airflow channels and the secondbaffle level includes a plurality of second airflow channels, andwherein each of the plurality of first airflow channels shares a wallwith one of the plurality of second airflow channels.
 3. The bafflecomponent of claim 2, wherein each first airflow channel of theplurality of first airflow channels is defined by a pair of fins spacedfrom one another and extending between the shared wall and a lower wall.4. The baffle component of claim 2, wherein the first baffle levelfurther includes an upper outer edge, and wherein the shared wallextends from the upper outer edge.
 5. The baffle component of claim 1,wherein the first baffle level and the second baffle level define afirst attachment feature at a first end and a second attachment featureat a second end, wherein the first and second attachment features areconfigured to facilitate connection between adjacent baffle sections,and wherein connected adjacent baffle sections define a substantiallycircular shape defining a first central axis.
 6. The baffle component ofclaim 5, wherein the baffle levels are arranged with one another suchthat a first airflow traveling through the first baffle level is in adirection substantially parallel with a second airflow traveling throughthe second baffle level.
 7. The baffle component of claim 5, wherein theshared wall is oriented at an angle substantially between zero andninety degrees relative to the first central axis defined by thesubstantially circular shape.
 8. The baffle component of claim 1,wherein the baffle levels are further arranged with one another suchthat airflow from the starter assembly is exhausted via two airflowchannels.
 9. The baffle component of claim 1, wherein each of the firstbaffle level and the second baffle level is formed via additivemanufacturing.
 10. The baffle component of claim 1, wherein the firstbaffle level includes a plurality of first airflow channels and thesecond baffle level includes a plurality of second airflow channels,wherein each first airflow channel of the plurality of first airflowchannels defines an airflow central plane, and wherein each secondairflow channel of the plurality of second airflow channels is orientedsubstantially parallel to the airflow central plane.
 11. A starterassembly comprising: a baffle component having a plurality of firstairflow channels, each first airflow channel being defined by a pair offins spaced from one another, a lower wall, and a shared wall, thebaffle component further having a plurality of second airflow channels,each second airflow channel being defined by one of the pairs of finsand the shared wall, wherein each of the pairs of fins extends throughthe shared wall such that each of the pairs of fins partially definesone of the plurality of first airflow channels and one of the pluralityof second airflow channels.
 12. The assembly of claim 11, wherein theplurality of second airflow channels is arranged in a stack with theplurality of first airflow channels such that the shared wall partiallydefines each airflow channel of the plurality of first airflow channelsand partially defines each airflow channel of the plurality of secondairflow channels.
 13. The assembly of claim 11, wherein the bafflecomponent is arranged to define a central axis, and wherein the bafflecomponent further has one or more posts, each post of the one or moreposts extending through the baffle levels and being disposed equidistantfrom the central axis.
 14. The assembly of claim 11, wherein the bafflecomponent comprises a plurality of components, and wherein each of theplurality of components includes a first end for securing to a firstadjacent component and a second end for securing to a second adjacentcomponent.
 15. The assembly of claim 14, wherein the plurality ofcomponents are arranged with one another to define a substantiallycircular shape about a baffle central axis.
 16. The assembly of claim15, wherein the plurality of components are arranged such that thebaffle central axis is oriented substantially perpendicular to an axisof an adjacent engine.
 17. The assembly of claim 11, wherein the bafflecomponent is comprised of more than one baffle section, wherein each ofthe more than one baffle sections is arranged with one another to definea central axis, and wherein the shared wall is oriented at an anglesubstantially between zero and ninety degrees relative to the centralaxis.
 18. The assembly of claim 11, wherein each airflow channel of theplurality of first airflow channels influences a first airflowtherethrough in a direction substantially parallel to an airflowdirection of a second airflow traveling through each airflow channel ofthe plurality of second airflow channels.
 19. The assembly of claim 11,wherein the baffle component is formed via additive manufacturing. 20.The assembly of claim 11, wherein each first airflow channel of theplurality of first airflow channels defines an airflow central plane,and wherein each second airflow channel of the plurality of secondairflow channels is oriented substantially parallel to the airflowcentral plane.